Horizontal Winding Shaft Exchange in Reverse Drum Winders

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Solution Overview

Problem

Reverse drum winders experience high loads and vibrations during roll changes, leading to frequent maintenance needs due to complex and prone-to-failure structures, which disrupt the winding process.

Innovation Solution

A method for exchanging a fully wound winding shaft with an unwound one within the reverse drum winder without tilting, using a transport device with opposing guide systems to move the winding shaft horizontally, ensuring continuous operation and eliminating vibrations by maintaining a support roller's continuous contact with the web material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a tilting movement is used to transport the roll from the first pair of support rollers to the second pair, then the roll change can be achieved, but the reverse drum winder is exposed to strong vibrations and high loads

Engineering Contradiction:

Improveroll change capabilityVSAvoidvibrations and high loads

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

Instead of tilting the support frame to move the roll horizontally, the invention inverts the approach by keeping the support frame stationary and moving the entire pair of support rollers horizontally along guide rails. This reversal of the movement mechanism eliminates the tilting action that causes vibrations and high loads, while still achieving the desired roll transport function.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention replaces the complex tilting mechanical system with a simpler horizontal translation mechanism. The support rollers are mounted on guide rails that allow horizontal movement, substituting the tilting motion with a linear sliding motion that does not generate vibrations or high loads on the winder structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If a movable support frame is used to pivot and transport the roll, then the roll can be moved between support roller pairs, but the structure becomes complicated and prone to failure

Engineering Contradiction:

Improveroll transport functionVSAvoidstructure complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The invention segments the support system into independent support rollers that can move horizontally along guide rails, rather than using a single integrated movable support frame. This segmentation allows each roller to be independently positioned and replaced, simplifying the overall structure and reducing the number of moving parts that can fail.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention extracts the movement function from the support frame structure itself and transfers it to the support rollers through guide rails. By taking out the tilting mechanism entirely and replacing it with simple horizontal sliding guides, the structure is simplified while retaining the essential roll transport capability.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If the support frame is pivoted to move the roll onto the second pair of support rollers, then the roll change is achieved, but frequent maintenance is required due to prone-to-failure components

Engineering Contradiction:

Improvecontinuous winding operationVSAvoidmaintenance frequency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Instead of moving the support frame to achieve roll changes, the invention inverts the approach by keeping the support frame stationary and moving the support rollers horizontally. This eliminates the pivoting action that causes mechanical wear and failure, significantly reducing maintenance requirements while maintaining continuous operation capability.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention replaces the complex pivoting mechanical system with a simple horizontal translation mechanism using guide rails. This substitution eliminates the mechanical stress and wear associated with pivoting, resulting in a more reliable system that requires less frequent maintenance while maintaining productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP2694415B1Method and device for switching winding shafts

Publication Date: 2016.06.22 PSA TECH S A R L

Figure 1
Figure 2a~2b
Figure 2c~2d

AI summary

The invention relates to a rearward supporting roller winder (1) for winding web-shaped materials (33) into wound rolls (34). The rolls can additionally be switched without interrupting the winding process using the rearward supporting roller winder (1). The rearward supporting roller winder (1) has a first supporting roller pair (18, 19) and a lay-on roller (11) which is arranged above the first supporting roller pair (18, 19) and which rests on the wound rolls (34) during almost the entire winding process. Furthermore, a second supporting roller pair (23, 24) is provided which is used to receive the completely wound rolls (34). Said second supporting roller pair (23, 24) can be moved horizontally away from the first supporting roller pair (18, 19) such that a gap is produced between the two supporting roller pairs (18, 19; 23, 24), a second winding shaft (52) being passed through said gap in order to move said winding shaft together with the web-shaped material (33) between the two supporting rollers of the first supporting roller pair (18, 19).